Active Passive Fuse Module Integrating Pyrotechnic Interrupter
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Solution Overview
Problem
Existing circuit protection systems lack a compact and efficient solution that combines both passive and active protection elements to safely de-energize electrical circuits in critical situations, such as vehicle collisions, to prevent damage and ensure safety.
Innovation Solution
An active/passive fuse module that integrates a pyrotechnic interrupter with a piston driven by pyrotechnic ignitors, both externally and arc-triggered, to physically open the circuit, along with a current sensing module and a positive temperature coefficient element for enhanced safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both passive and active circuit protection elements are implemented, then circuit protection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines passive fuse elements and active pyrotechnic interrupters into a single integrated fuse module. The passive fuse element provides continuous overcurrent protection, while the active pyrotechnic interrupter provides rapid circuit opening capability. Both protection mechanisms are merged into one device that occupies a single circuit protection slot, achieving reliable dual-mode protection without proportionally increasing system complexity.
Solution Approach 2:
The fuse module serves multiple functions: it provides passive overcurrent protection through the fuse element, active circuit opening through the pyrotechnic interrupter, and arc suppression through the enclosed chamber design. This multi-functionality allows a single device to replace what would traditionally require separate protection components, improving reliability while managing complexity.
2Reliability
If a pyrotechnic interrupter is added to the fuse module, then active circuit opening capability is improved, but device volume increases
Solution Approach 1:
The pyrotechnic interrupter mechanism is nested within the fuse module housing. The piston and shaft components are contained within the enclosed chamber, with the fuse element positioned to be severed by the piston's linear motion. This nesting arrangement allows the active protection mechanism to be integrated within the existing fuse form factor, minimizing volume increase while adding critical active opening capability.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning the pyrotechnic interrupter shaft and piston to move vertically through the fuse element. This vertical arrangement allows the active interrupter mechanism to be stacked above the passive fuse element, efficiently using three-dimensional space within the module housing rather than requiring additional horizontal space.
3Reliability
If the fuse element is positioned to be severed by piston motion, then active interrupting effectiveness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The fuse element is pre-positioned within the enclosed chamber such that its location relative to the piston's travel path is established during manufacturing. The piston is configured to travel along a predetermined linear path that intersects the fuse element at a specific point. This preliminary positioning ensures that when the pyrotechnic ignitor activates the piston, the severing action occurs reliably without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The enclosed chamber design provides self-alignment features that guide the piston's linear motion and ensure consistent positioning relative to the fuse element. The chamber walls and mounting structures are designed to automatically position components correctly during assembly, reducing the need for high-precision manual adjustment and maintaining manufacturing feasibility while ensuring effective active interrupting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The module effectively interrupts electrical current in a compact form factor, preventing damage and ensuring safety by combining passive and active protection elements, allowing for convenient installation and robust handling of high currents.
Implementation Method 1
a pyrotechnic interrupter (PI) disposed atop the base, the PI including a piston disposed within a shaft above the fuse element, a pyrotechnic ignitor coupled to the controller, the pyrotechnic ignitor configured to detonate and force the piston through the fuse element upon receiving an initiation signal from the controller
Implementation Method 2
Most fuses are 'passive' devices that include fuse elements that are configured to carry a rated amount of electrical current during normal operation. If current flowing through a fuse element exceeds the fuse element's rated current, the fuse element will melt, disintegrate, or otherwise separate
Implementation Method 3
along with a current sensing module and a positive temperature coefficient element for enhanced safety and reliability
Data Source
AI summary
An active/passive fuse module including a base, a busbar disposed on a top surface of the base and including a fuse element and first and second terminal portions extending from opposite ends of the fuse element, the fuse element extending over a cavity in the top surface of the base, a pyrotechnic interrupter (PI) disposed atop the base, the PI including a piston disposed within a shaft above the fuse element, a first pyrotechnic ignitor coupled to a controller, the first pyrotechnic ignitor configured to detonate and force the piston through the fuse element upon receiving an initiation signal from the controller, and a second pyrotechnic ignitor coupled to the busbar by a pair of leads, the second pyrotechnic ignitor configured to detonate and force the piston through the fuse element upon an increase in voltage across the leads.